Robotic surgery system for augmented hip arthroplasty procedures

ABSTRACT

A system for facilitating arthroplasty procedures includes a robotic device, a reaming tool configured to interface with the robotic device, and a processing circuit communicable with the robotic device. The processing circuit is configured to obtain a surgical plan comprising a first planned position of an implant cup and a second planned position of an implant augment relative to a bone of a patient, determine a planned bone modification configured to prepare the bone to receive the implant cup in the first planned position and the implant augment in the second planned position, generate one or more virtual objects based on the planned bone modification, control the robotic device to constrain the cutting tool with the one or more virtual objects while the cutting tool interfaces with the robotic device and is operated to modify the bone in accordance with the planned bone modification.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of and priority to U.S. ProvisionalApplication No. 62/893,384 filed Aug. 29, 2019, the entire disclosure ofwhich is incorporated by reference herein.

BACKGROUND

The present disclosure relates generally to surgical systems fororthopedic surgeries, and more particularly to surgical systems fortotal and partial hip arthroplasty procedures. Hip arthroplasty,colloquially referred to as hip replacement, is widely used to treat hiposteoarthritis and other damage to a patient's hip joint by replacingportions of the hip anatomy with prosthetic components.

One possible tool for use in total hip arthroplasty procedure is arobotically-assisted surgical system. A robotically-assisted surgicalsystem typically includes a robotic device that is used to prepare apatient's anatomy, a tracking system configured to monitor the locationof the robotic device relative to the patient's anatomy, and a computingsystem configured to monitor and control the robotic device.Robotically-assisted surgical systems, in various forms, autonomouslycarry out surgical tasks, provide force feedback to a user manipulatinga surgical device to complete surgical tasks, augment surgeon dexterityand precision, and/or provide other navigational cues to facilitate safeand accurate surgical operations.

A surgical plan is typically established prior to performing a surgicalprocedure with a robotically-assisted surgical system. Based on thesurgical plan, the surgical system guides, controls, or limits movementsof the surgical tool during portions of the surgical procedure. Guidanceand/or control of the surgical tool serves to protect the patient and toassist the surgeon during implementation of the surgical plan.

SUMMARY

One implementation of the present disclosure is a system forfacilitating arthroplasty procedures. The system includes a roboticdevice, a reaming tool configured to interface with the robotic device,and a processing circuit communicable with the robotic device. Theprocessing circuit is configured to obtain a surgical plan comprising afirst planned position of an implant cup and a second planned positionof an implant augment relative to a bone of a patient, determine aplanned bone modification configured to prepare the bone to receive theimplant cup in the first planned position and the implant augment in thesecond planned position, generate one or more virtual objects based onthe planned bone modification, control the robotic device to constrainthe cutting tool with the one or more virtual objects while the cuttingtool interfaces with the robotic device and is operated to modify thebone in accordance with the planned bone modification.

Another implementation of the present disclosure is a method. The methodincludes obtaining a surgical plan including a first planned position ofan implant cup and a second planned position of an implant augmentrelative to a bone of a patient, determining a planned bone modificationconfigured to prepare the bone to receive the implant cup in the firstplanned position and the implant augment in the second planned position,generating one or more virtual objects based on the planned bonemodification, and controlling a robotic device using the one or morevirtual objects to facilitate modification of the bone with a surgicaltool interfacing with the robotic device in accordance with the plannedbone modification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a femur and a pelvis.

FIG. 1B is a perspective view of a hip joint formed by the femur andpelvis of FIG. 1A.

FIG. 1C is an exploded perspective view of a femoral component and anacetabular component for a total hip replacement procedure.

FIG. 1D is a perspective view illustrating placement of the femoralcomponent and acetabular component of FIG. 1C in relation to the femurand pelvis of FIG. 1A, respectively.

FIG. 2 is an illustration of a surgical system, according to anexemplary embodiment.

FIG. 3 is a flowchart of a process for facilitating an arthroplastyprocedure, according to an exemplary embodiment.

FIG. 4 is a first illustration of a graphical user interface that can beused with the process of FIG. 3, according to an exemplary embodiment.

FIG. 5 is a second illustration of a graphical user interface that canbe used with the process of FIG. 3, according to an exemplaryembodiment.

FIG. 6 is a third illustration of a graphical user interface that can beused with the process of FIG. 3, according to an exemplary embodiment.

FIG. 7 is a fourth illustration of a graphical user interface that canbe used with the process of FIG. 3, according to an exemplaryembodiment.

FIG. 8 is a flowchart of showing a detailed view of steps of the processof FIG. 3, according to an exemplary embodiment.

FIG. 9 is a first visualization of registration regions on a pelvis foruse with the process of FIG. 3, according to an exemplary embodiment.

FIG. 10 is a second visualization of registration regions on a pelvisfor use with the process of FIG. 3, according to an exemplaryembodiment.

FIG. 11 is a fifth illustration of a graphical user interface that canbe used with the process of FIG. 3, according to an exemplaryembodiment.

FIG. 12 is a sixth illustration of a graphical user interface that canbe used with the process of FIG. 3, according to an exemplaryembodiment.

FIG. 13 is a depiction of an implant augment and a probe as used in theprocess of FIG. 3, according to an exemplary embodiment.

FIG. 14 is a depiction of fixation of the implant augment of FIG. 13 toa bone as in the process of FIG. 3, according to an exemplaryembodiment.

FIG. 15 is a depiction of a cup impaction step of the process of FIG. 3,according to an exemplary embodiment.

FIG. 16 is a depiction of a cement curing step of the process of FIG. 3,according to an exemplary embodiment.

FIG. 17 is a flowchart of a process for facilitating a knee arthroplastyprocedure that includes a tibial or femoral augment, according to anexemplary embodiment.

FIG. 18 is a first illustration of a tibial template and a probe as usedin the process of FIG. 17, according to an exemplary embodiment.

FIG. 19 is a second illustration of a tibial template and a probe asused in the process of FIG. 17, according to an exemplary embodiment.

FIG. 20 is a first illustration of a femoral trial and a probe as usedin the process of FIG. 17, according to an exemplary embodiment.

FIG. 21 is a second illustration of a femoral trial and a probe as usedin the process of FIG. 17, according to an exemplary embodiment.

FIG. 22 is a perspective view of a tibial implant and a tibial augment,according to an exemplary embodiment.

FIG. 23 is a perspective view of a femoral implant and a pair of femoralaugments, according to an exemplary embodiment.

DETAILED DESCRIPTION

Presently preferred embodiments of the invention are illustrated in thedrawings. An effort has been made to use the same or like referencenumbers throughout the drawings to refer to the same or like parts.Although this specification refers primarily to a robotic arm fororthopedic hip replacement, it should be understood that the subjectmatter described herein is applicable to other types of robotic systems,including those used for surgical and non-surgical applications, as wellas to other joints of the body, such as, for example, a knee or shoulderjoint.

The hip joint is the joint between the femur and the pelvis andprimarily functions to support the weight of the body in static (forexample, standing) and dynamic (for example, walking) postures. FIG. 1Aillustrates the bones of a hip joint 10, which include a pelvis 12(shown in part) and a proximal end of a femur 14. The proximal end ofthe femur 14 includes a femoral head 16 disposed on a femoral neck 18.The femoral neck 18 connects the femoral head 16 to a femoral shaft 20.As shown in FIG. 1B, the femoral head 16 fits into a concave socket inthe pelvis 12 called the acetabulum 22, thereby forming the hip joint10. The acetabulum 22 and femoral head 16 are both covered by articularcartilage that absorbs shock and promotes articulation of the joint 10.

Over time, the hip joint 10 may degenerate (for example, due toosteoarthritis) resulting in pain and diminished functionality. As aresult, a hip replacement procedure, such as total hip arthroplasty orhip resurfacing, may be necessary. During hip replacement, a surgeonreplaces portions of a patient's hip joint 10 with artificialcomponents. In total hip arthroplasty, the surgeon removes the femoralhead 16 and neck 18 and replaces the natural bone with a prostheticfemoral component 26 comprising a head 26 a, a neck 26 b, and a stem 26c (shown in FIG. 1C). As shown in FIG. 1D, the stem 26 c of the femoralcomponent 26 is anchored in a cavity the surgeon creates in theintramedullary canal of the femur 14. Alternatively, if disease isconfined to the surface of the femoral head 16, the surgeon may opt fora less invasive approach in which the femoral head is resurfaced (e.g.,using a cylindrical reamer) and then mated with a prosthetic femoralhead cup (not shown).

Similarly, if the natural acetabulum 22 of the pelvis 12 is worn ordiseased, the surgeon resurfaces the acetabulum 22 using a reamer andreplaces the natural surface with a prosthetic acetabular component 28comprising a hemispherical shaped cup 28 a (shown in FIG. 1C) that mayinclude a liner 28 b. To install the acetabular component 28, thesurgeon connects the cup 28 a to a distal end of an impactor tool andimplants the cup 28 a into the reamed acetabulum 22 by repeatedlystriking a proximal end of the impactor tool with a mallet. If theacetabular component 28 includes a liner 28 b, the surgeon snaps theliner 28 b into the cup 28 a after implanting the cup 28 a. Depending onthe position in which the surgeon places the patient for surgery, thesurgeon may use a straight or offset reamer to ream the acetabulum 22and a straight or offset impactor to implant the acetabular cup 28 a.For example, a surgeon that uses a postero-lateral approach may preferstraight reaming and impaction whereas a surgeon that uses anantero-lateral approach may prefer offset reaming and impaction.

In some cases, an implant augment is used to support or otherwisefacilitate reconstruction of the acetabulum 22 to facilitate fixation ofthe cup 28 a to the pelvis 12 in a preferred position and orientation.Use of an augment may be preferable in several scenarios. As oneexample, an implant augment may be advantageous post-traumatic hipreconstructions, in which a traumatic injury (e.g., car crash, etc.)caused damage to the pelvis 12. As another example, an implant augmentmay be advantageous in cases of hip dysplasia or other cases ofacetabular bone loss, i.e., to fill space created by such bone loss. Asanother example, an implant augment may be advantageous for revision hiparthroplasty procedures, in which a previously-implanted hip prosthesisis removed and replaced with a new implant due to degradation ofneighboring bone or other complications.

Current surgical procedures that involve implant augments typically relyon surgeon expertise and experience to manually place an implant augmentin a position that looks and feels correct to the surgeonintraoperatively. Such procedures may be difficult and result inextended surgical time. Additionally, currently-availablerobotically-assisted surgical devices for hip arthroplasty do notprovide for placement of implant augments. The systems and methodsdescribed herein provide for computer-assisted planning of implantplacement and robotically-assisted surgical steps to facilitate bonepreparation for implant augments and placement of implant augmentsduring hip arthroplasty procedures, thereby facilitating hiparthroplasty procedures in cases of bone loss, traumatic injury,revision hip replacements, or other relevant scenarios. The systems andmethods described herein may thereby improve patient outcomes, reducesurgery times, and reduce the burden on surgeons for augmented hiparthroplasty procedures.

Referring now to FIG. 2, a surgical system 200 for orthopedic surgery isshown, according to an exemplary embodiment. In general, the surgicalsystem 200 is configured to facilitate the planning and execution of asurgical plan, for example to facilitate a joint-related procedure. Asshown in FIG. 2, the surgical system 200 is set up to treat a leg 202 ofa patient 204 sitting or lying on table 205. In the illustration shownin FIG. 2, the leg 202 includes femur 206 and tibia 208, between which aprosthetic knee implant is to be implanted in a total knee arthroscopyprocedure. The scenario shown in FIG. 2 may correspond to thedescription below with reference to FIGS. 17-22. In other scenarios, forexample as described herein with reference to 1A-1D and FIGS. 3-16, thesurgical system 200 is set up to treat the hip 10 of a patient, i.e.,the femur 14 and the pelvis 12 of the patient (illustrated in FIGS.1A-1D). Additionally, in still other scenarios, the surgical system 200is set up to treat a shoulder of a patient, i.e., to facilitatereplacement and/or augmentation of components of a shoulder joint (e.g.,to facilitate placement of a humeral component, a glenoid component, anda graft or implant augment). Various other anatomical regions andprocedures are also possible. To facilitate the procedure, surgicalsystem 200 includes robotic device 220, tracking system 222, andcomputing system 224.

The robotic device 220 is configured to modify a patient's anatomy(e.g., femur 206 of patient 204) under the control of the computingsystem 224. One embodiment of the robotic device 220 is a haptic device.“Haptic” refers to a sense of touch, and the field of haptics relatesto, among other things, human interactive devices that provide feedbackto an operator. Feedback may include tactile sensations such as, forexample, vibration. Feedback may also include providing force to a user,such as a positive force or a resistance to movement. One use of hapticsis to provide a user of the device with guidance or limits formanipulation of that device. For example, a haptic device may be coupledto a surgical tool, which can be manipulated by a surgeon to perform asurgical procedure. The surgeon's manipulation of the surgical tool canbe guided or limited through the use of haptics to provide feedback tothe surgeon during manipulation of the surgical tool.

Another embodiment of the robotic device 220 is an autonomous orsemi-autonomous robot. “Autonomous” refers to a robotic device's abilityto act independently or semi-independently of human control by gatheringinformation about its situation, determining a course of action, andautomatically carrying out that course of action. For example, in suchan embodiment, the robotic device 220, in communication with thetracking system 222 and the computing system 224, may autonomouslycomplete the series of femoral cuts mentioned above without direct humanintervention.

The robotic device 220 includes a base 230, a robotic arm 232, and asurgical tool 234, and is communicably coupled to the computing system224 and the tracking system 222. The base 230 provides a moveablefoundation for the robotic arm 232, allowing the robotic arm 232 and thesurgical tool 234 to be repositioned as needed relative to the patient204 and the table 205. The base 230 may also contain power systems,computing elements, motors, and other electronic or mechanical systemnecessary for the functions of the robotic arm 232 and the surgical tool234 described below.

The robotic arm 232 is configured to support the surgical tool 234 andprovide a force as instructed by the computing system 224. In someembodiments, the robotic arm 232 allows a user to manipulate thesurgical tool and provides force feedback to the user. In such anembodiment, the robotic arm 232 includes joints 236 and mount 238 thatinclude motors, actuators, or other mechanisms configured to allow auser to freely translate and rotate the robotic arm 232 and surgicaltool 234 through allowable poses while providing force feedback toconstrain or prevent some movements of the robotic arm 232 and surgicaltool 234 as instructed by computing system 224. As described in detailbelow, the robotic arm 232 thereby allows a surgeon to have full controlover the surgical tool 234 within a control object while providing forcefeedback along a boundary of that object (e.g., a vibration, a forcepreventing or resisting penetration of the boundary). In someembodiments, the robotic arm is configured to move the surgical tool toa new pose automatically without direct user manipulation, as instructedby computing system 224, in order to position the robotic arm as neededand/or complete certain surgical tasks, including, for example, cuts ina femur 206 or an acetabulum.

The surgical tool 234 is configured to cut, burr, grind, drill,partially resect, reshape, and/or otherwise modify a bone. The surgicaltool 234 may be any suitable tool, and may be one of multiple toolsinterchangeably connectable to robotic device 220. For example, as shownin FIG. 2 the surgical tool 234 is a spherical burr. The surgical toolmay also be a sagittal saw, for example with a blade aligned parallelwith a tool axis or perpendicular to the tool axis. The surgical tool234 may also be a holding arm or other support configured to hold animplant component (e.g., cup 28 a, implant augment, etc.) in positionwhile the implant component is screwed to a bone, adhered (e.g.,cemented) to a bone or other implant component, or otherwise installedin a preferred position. In some embodiments, the surgical tool 234 isan impaction tool configured to provide an impaction force to a cup 28 ato facilitate fixation of the cup 28 a to a pelvis 12 in a plannedlocation and orientation.

Tracking system 222 is configured to track the patient's anatomy (e.g.,femur 206 and tibia 208) and the robotic device 220 (i.e., surgical tool234 and/or robotic arm 232) to enable control of the surgical tool 234coupled to the robotic arm 232, to determine a position and orientationof modifications or other results made by the surgical tool 234, andallow a user to visualize the bones (e.g., femur 206, the tibia 208,pelvis 12, humerus, scapula, etc. as applicable in various procedures),the surgical tool 234, and/or the robotic arm 232 on a display of thecomputing system 224. More particularly, the tracking system 222determines a position and orientation (i.e., pose) of objects (e.g.,surgical tool 234, femur 206) with respect to a coordinate frame ofreference and tracks (i.e., continuously determines) the pose of theobjects during a surgical procedure. According to various embodiments,the tracking system 222 may be any type of navigation system, includinga non-mechanical tracking system (e.g., an optical tracking system), amechanical tracking system (e.g., tracking based on measuring therelative angles of joints 236 of the robotic arm 232), or anycombination of non-mechanical and mechanical tracking systems.

In the embodiment shown in FIG. 2, the tracking system 222 includes anoptical tracking system. Accordingly, tracking system 222 includes afirst fiducial tree 240 coupled to the tibia 208, a second fiducial tree241 coupled to the femur 206, a third fiducial tree 242 coupled to thebase 230, one or more fiducials coupled to surgical tool 234, and adetection device 246 configured to detect the three-dimensional positionof fiducials (i.e., markers on fiducial trees 240-242). Fiducial trees240, 241 may be coupled to other bones as suitable for variousprocedures (e.g., pelvis 12 and femur 206 in a hip arthroplastyprocedure). Detection device 246 may be an optical detector such as acamera or infrared sensor. The fiducial trees 240-242 include fiducials,which are markers configured to show up clearly to the optical detectorand/or be easily detectable by an image processing system using datafrom the optical detector, for example by being highly reflective ofinfrared radiation (e.g., emitted by an element of tracking system 222).A stereoscopic arrangement of cameras on detection device 246 allows theposition of each fiducial to be determined in 3D-space through atriangulation approach. Each fiducial has a geometric relationship to acorresponding object, such that tracking of the fiducials allows for thetracking of the object (e.g., tracking the second fiducial tree 241allows the tracking system 222 to track the femur 206), and the trackingsystem 222 may be configured to carry out a registration process todetermine or verify this geometric relationship. Unique arrangements ofthe fiducials in the fiducial trees 240-242 (i.e., the fiducials in thefirst fiducial tree 240 are arranged in a different geometry thanfiducials in the second fiducial tree 241) allows for distinguishing thefiducial trees, and therefore the objects being tracked, from oneanother.

Using the tracking system 222 of FIG. 2 or some other approach tosurgical navigation and tracking, the surgical system 200 can determinethe position of the surgical tool 234 relative to a patient's anatomicalfeature, for example femur 206, as the surgical tool 234 is used tomodify the anatomical feature or otherwise facilitate the surgicalprocedure. Additionally, using the tracking system 222 of FIG. 2 or someother approach to surgical navigation and tracking, the surgical system200 can determine the relative poses of the tracked bones.

The computing system 224 is configured to create a surgical plan,control the robotic device 220 in accordance with the surgical plan tomake one or more bone modifications and/or facilitate implantation ofone or more prosthetic components. Accordingly, the computing system 224is communicably coupled to the tracking system 222 and the roboticdevice 220 to facilitate electronic communication between the roboticdevice 220, the tracking system 222, and the computing system 224.Further, the computing system 224 may be connected to a network toreceive information related to a patient's medical history or otherpatient profile information, medical imaging, surgical plans, surgicalprocedures, and to perform various functions related to performance ofsurgical procedures, for example by accessing an electronic healthrecords system. Computing system 224 includes processing circuit 260 andinput/output device 262.

The input/output device 262 is configured to receive user input anddisplay output as needed for the functions and processes describedherein. As shown in FIG. 2, input/output device 262 includes a display264 and a keyboard 266. The display 264 is configured to displaygraphical user interfaces generated by the processing circuit 260 thatinclude, for example, information about surgical plans, medical imaging,settings and other options for surgical system 200, status informationrelating to the tracking system 222 and the robotic device 220, andtracking visualizations based on data supplied by tracking system 222.The keyboard 266 is configured to receive user input to those graphicaluser interfaces to control one or more functions of the surgical system200.

The processing circuit 260 includes a processor and memory device. Theprocessor can be implemented as a general purpose processor, anapplication specific integrated circuit (ASIC), one or more fieldprogrammable gate arrays (FPGAs), a group of processing components, orother suitable electronic processing components. The memory device(e.g., memory, memory unit, storage device, etc.) is one or more devices(e.g., RAM, ROM, Flash memory, hard disk storage, etc.) for storing dataand/or computer code for completing or facilitating the variousprocesses and functions described in the present application. The memorydevice may be or include volatile memory or non-volatile memory. Thememory device may include database components, object code components,script components, or any other type of information structure forsupporting the various activities and information structures describedin the present application. According to an exemplary embodiment, thememory device is communicably connected to the processor via theprocessing circuit 260 and includes computer code for executing (e.g.,by the processing circuit 260 and/or processor) one or more processesdescribed herein.

More particularly, processing circuit 260 is configured to facilitatethe creation of a preoperative surgical plan prior to the surgicalprocedure. According to some embodiments, the preoperative surgical planis developed utilizing a three-dimensional representation of a patient'sanatomy, also referred to herein as a “virtual bone model.” A “virtualbone model” may include virtual representations of cartilage or othertissue in addition to bone. To obtain the virtual bone model, theprocessing circuit 260 receives imaging data of the patient's anatomy onwhich the surgical procedure is to be performed (e.g., femur 206, pelvis12). The imaging data may be created using any suitable medical imagingtechnique to image the relevant anatomical feature, including computedtomography (CT), magnetic resonance imaging (MM), and/or ultrasound. Theimaging data is then segmented (i.e., the regions in the imagingcorresponding to different anatomical features are distinguished) toobtain the virtual bone model. For example, as described in furtherdetail below, MRI-based scan data of a hip can be segmented todistinguish the femur from surrounding ligaments, cartilage,previously-implanted prosthetic components, and other tissue to obtain athree-dimensional model of the imaged hip.

Alternatively, the virtual bone model may be obtained by selecting athree-dimensional model from a database or library of bone models. Inone embodiment, the user may use input/output device 262 to select anappropriate model. In another embodiment, the processing circuit 260 mayexecute stored instructions to select an appropriate model based onimages or other information provided about the patient. The selectedbone model(s) from the database can then be deformed based on specificpatient characteristics, creating a virtual bone model for use insurgical planning and implementation as described herein.

A preoperative surgical plan can then be created based on the virtualbone model. The surgical plan may be automatically generated by theprocessing circuit 260, input by a user via input/output device 262, orsome combination of the two (e.g., the processing circuit 260 limitssome features of user-created plans, generates a plan that a user canmodify, etc.). In some embodiments, as described in detail below, thesurgical plan may be generated and/or modified based on distractionforce measurements collected intraoperatively. In some embodiments, thesurgical plan may be modified based on qualitative intra-operationalassessment of implant fixation (i.e., loose or fixed) and/orintra-operative bone defect mapping after primary implant removal, forexample as described in detail below.

The preoperative surgical plan includes the desired cuts, holes,surfaces, burrs, or other modifications to a patient's anatomy to bemade using the surgical system 200. For example, for a total kneearthroscopy procedure, the preoperative plan may include the cutsnecessary to form, on a femur, a distal surface, a posterior chamfersurface, a posterior surface, an anterior surface, and an anteriorchamfer surface in relative orientations and positions suitable to bemated to corresponding surfaces of the prosthetic to be joined to thefemur during the surgical procedure, as well as cuts necessary to form,on the tibia, surface(s) suitable to mate to the prosthetic to be joinedto the tibia during the surgical procedure. As another example, in a hiparthroplasty procedure, the surgical plan may include the burr necessaryto form one or more surfaces on the acetabular region of the pelvis 12to receive a cup 28(a) and, in suitable cases, an implant augment.Accordingly, the processing circuit 260 may receive, access, and/orstore a model of the prosthetic to facilitate the generation of surgicalplans.

The processing circuit 260 is further configured to generate a controlobject for the robotic device 220 in accordance with the surgical plan.The control object may take various forms according to the various typesof possible robotic devices (e.g., haptic, autonomous, etc). Forexample, in some embodiments, the control object defines instructionsfor the robotic device to control the robotic device to move within thecontrol object (i.e., to autonomously make one or more cuts of thesurgical plan guided by feedback from the tracking system 222). In someembodiments, the control object includes a visualization of the surgicalplan and the robotic device on the display 264 to facilitate surgicalnavigation and help guide a surgeon to follow the surgical plan (e.g.,without active control or force feedback of the robotic device). Inembodiments where the robotic device 220 is a haptic device, the controlobject may be a haptic object as described in the following paragraphs.

In an embodiment where the robotic device 220 is a haptic device, theprocessing circuit 260 is further configured to generate one or morehaptic objects based on the preoperative surgical plan to assist thesurgeon during implementation of the surgical plan by enablingconstraint of the surgical tool 234 during the surgical procedure. Ahaptic object may be formed in one, two, or three dimensions. Forexample, a haptic object can be a line, a plane, or a three-dimensionalvolume. A haptic object may be curved with curved surfaces and/or haveflat surfaces, and can be any shape, for example a funnel shape. Hapticobjects can be created to represent a variety of desired outcomes formovement of the surgical tool 234 during the surgical procedure. One ormore of the boundaries of a three-dimensional haptic object mayrepresent one or more modifications, such as cuts, to be created on thesurface of a bone. A planar haptic object may represent a modification,such as a cut, to be created on the surface of a bone. A curved hapticobject may represent a resulting surface of a bone as modified toreceive a cup 28 a and/or implant augment.

In an embodiment where the robotic device 220 is a haptic device, theprocessing circuit 260 is further configured to generate a virtual toolrepresentation of the surgical tool 234. The virtual tool includes oneor more haptic interaction points (HIPs), which represent and areassociated with locations on the physical surgical tool 234. In anembodiment in which the surgical tool 234 is a spherical burr (e.g., asshown in FIG. 2), a HIP may represent the center of the spherical burr.If the surgical tool 234 is an irregular shape, for example as for asagittal saw, the virtual representation of the sagittal saw may includenumerous HIPs. Using multiple HIPs to generate haptic forces (e.g.positive force feedback or resistance to movement) on a surgical tool isdescribed in U.S. application Ser. No. 13/339,369, titled “System andMethod for Providing Substantially Stable Haptics,” filed Dec. 28, 2011,and hereby incorporated by reference herein in its entirety. In oneembodiment of the present invention, a virtual tool representing asagittal saw includes eleven HIPs. As used herein, references to an“HIP” are deemed to also include references to “one or more HIPs.” Asdescribed below, relationships between HIPs and haptic objects enablethe surgical system 200 to constrain the surgical tool 234.

Prior to performance of the surgical procedure, the patient's anatomy(e.g., femur 206) is registered to the virtual bone model of thepatient's anatomy by any known registration technique. One possibleregistration technique is point-based registration, as described in U.S.Pat. No. 8,010,180, titled “Haptic Guidance System and Method,” grantedAug. 30, 2011, and hereby incorporated by reference herein in itsentirety. Alternatively, registration may be accomplished by 2D/3Dregistration utilizing a hand-held radiographic imaging device, asdescribed in U.S. application Ser. No. 13/562,163, titled “RadiographicImaging Device,” filed Jul. 30, 2012, and hereby incorporated byreference herein in its entirety. Registration also includesregistration of the surgical tool 234 to a virtual tool representationof the surgical tool 234, so that the surgical system 200 can determineand monitor the pose of the surgical tool 234 relative to the patient(i.e., to femur 206). Registration of allows for accurate navigation,control, and/or force feedback during the surgical procedure. Additionaldetails relating to registration for hip arthroplasty procedures in someembodiments are described in detail below.

The processing circuit 260 is configured to monitor the virtualpositions of the virtual tool representation, the virtual bone model,and the control object (e.g., virtual haptic objects) corresponding tothe real-world positions of the patient's bone (e.g., femur 206), thesurgical tool 234, and one or more lines, planes, or three-dimensionalspaces defined by forces created by robotic device 220. For example, ifthe patient's anatomy moves during the surgical procedure as tracked bythe tracking system 222, the processing circuit 260 correspondinglymoves the virtual bone model. The virtual bone model thereforecorresponds to, or is associated with, the patient's actual (i.e.physical) anatomy and the position and orientation of that anatomy inreal/physical space. Similarly, any haptic objects, control objects, orother planned automated robotic device motions created during surgicalplanning that are linked to cuts, modifications, etc. to be made to thatanatomy also move in correspondence with the patient's anatomy. In someembodiments, the surgical system 200 includes a clamp or brace tosubstantially immobilize the femur 206 to minimize the need to track andprocess motion of the femur 206.

For embodiments where the robotic device 220 is a haptic device, thesurgical system 200 is configured to constrain the surgical tool 234based on relationships between HIPs and haptic objects. That is, whenthe processing circuit 260 uses data supplied by tracking system 222 todetect that a user is manipulating the surgical tool 234 to bring a HIPin virtual contact with a haptic object, the processing circuit 260generates a control signal to the robotic arm 232 to provide hapticfeedback (e.g., a force, a vibration) to the user to communicate aconstraint on the movement of the surgical tool 234. In general, theterm “constrain,” as used herein, is used to describe a tendency torestrict movement. However, the form of constraint imposed on surgicaltool 234 depends on the form of the relevant haptic object. A hapticobject may be formed in any desirable shape or configuration. As notedabove, three exemplary embodiments include a line, plane, orthree-dimensional volume. In one embodiment, the surgical tool 234 isconstrained because a HIP of surgical tool 234 is restricted to movementalong a linear haptic object. In another embodiment, the haptic objectis a three-dimensional volume and the surgical tool 234 may beconstrained by substantially preventing movement of the HIP outside ofthe volume enclosed by the walls of the three-dimensional haptic object.In another embodiment, the surgical tool 234 is constrained because aplanar haptic object substantially prevents movement of the HIP outsideof the plane and outside of the boundaries of the planar haptic object.For example, the processing circuit 260 can establish a planar hapticobject corresponding to a planned planar distal cut needed to create adistal surface on the femur 206 in order to confine the surgical tool234 substantially to the plane needed to carry out the planned distalcut.

For embodiments where the robotic device 220 is an autonomous device,the surgical system 200 is configured to autonomously move and operatethe surgical tool 234 in accordance with the control object. Forexample, the control object may define areas relative to the femur 206for which a cut should be made. In such a case, one or more motors,actuators, and/or other mechanisms of the robotic arm 232 and thesurgical tool 234 are controllable to cause the surgical tool 234 tomove and operate as necessary within the control object to make aplanned cut, for example using tracking data from the tracking system222 to allow for closed-loop control.

Referring now to FIG. 3, a flowchart of a process 300 for planning andconducting a hip arthroplasty procedure is shown, according to anexemplary embodiment. Process 300 can be executed by the surgical system200 of FIG. 2. Additionally, FIGS. 4-16 show various systems, methods,graphical user interfaces, etc. used in process 300. Reference is madethereto to facilitate explanation of process 300. It should beunderstood that process 300 is not limited to the examples of FIGS.4-16. Additionally, although FIGS. 3-16 illustrate embodiments ofprocess 300 for planning and conducting a procedure relating to a hip,other embodiments are possible for planning and conducting proceduresrelating to other anatomy, for example shoulders or knees.

At step 301, medical images of the hip joint are received and segmentedto generate a virtual bone model of the pelvis. For example, the medicalimages may be collected using CT technology, Mill technology, or someother medical imaging modality. The images are then segmented, i.e.,processed to differentiate areas of the images that correspond to thepelvis, the femur, soft tissue, and/or one or more previously-implantedprosthetic components.

In revision hip arthroplasty cases (i.e., where a previously-implantedcup is shown in the images), a determination may be made of whether thepreviously-implanted cup is “fixed” (i.e., substantially rigidly coupledto the pelvis) or “loose” (i.e., at least partially detached from thepelvis”). If the previously-implanted cup is fixed, the shape, position,etc. of previously-implanted cup may be determined and included in thevirtual bone model of the pelvis, for example to facilitate registrationat step 306 as described in detail below. If the previously-implantedcup is loose, the previously-implanted cup may be segmented out suchthat the loose cup is not included in the virtual bone model of thepelvis. Additionally, various corrections may be introduced to addressdistortions in CT or other imagery that may be caused by the materialsof the previously-implanted cup and/or movement of a loose cup duringimaging.

In some embodiments, step 301 is achieved automatically by theprocessing circuit 260 or other computing resource. In otherembodiments, human input is used in cooperation with automated functionsto achieve the segmentation and model generation of step 301.

At step 302, placement of an implant cup relative to the pelvis isplanned by virtually placing a virtual cup model relative to a virtualbone model, i.e., relative to the virtual model of the pelvis generatedat step 301 and, in some cases relative to previously-implantedcomponents (e.g., primary cup, fracture plates, compression screws,etc.). The virtual cup model is a virtual representation of the cupimplant to be implanted into the patient during the surgical procedure.Various cup sizes, shapes, types, etc. may be possible, and a differentvirtual cup model available for each cup. The virtual cup model isplaced to provide a desired center of rotation for the hip joint (e.g.,relative to the pelvis, relative to a patient's other hip, etc.) andensure a full range of motion. Various software planning tools may beprovided via the surgical system 100 to facilitate a surgeon or otheruser in selecting and evaluating the pose of the virtual cup model.

FIGS. 4-5 illustrate graphical user interfaces that can be generated bythe processing circuit 260 and displayed on the display 264 tofacilitate planning of cup placement at step 302. FIG. 4 shows a2-dimensional visualization of a planned cup pose relative to CT imagesreceived at step 301. FIG. 5 shows a 3-dimensional visualization of theplanned cup pose relative to a virtual bone model generated at step 301.Both are described in further detail below.

In FIG. 4, the graphical user interface 400 includes a first CT image402 overlaid with a representation of the virtual implant cup 404. Acenter point (center of rotation) 406 of the virtual implant cup 404 isalso shown. Additionally, as shown in FIG. 4, the graphical userinterface 400 visualizes the previous center point 408 of the joint asimaged, i.e., before the surgical operation. In the example of FIG. 4,the graphical user interface 400 also shows a second CT image 410 (e.g.,taken in a different plane) which is also overlaid with the virtualimplant cup 404, the center point 406, and the previous center point408. Advantageously, bone density information may be visible in the CTimages 402, 410. The graphical user interface 400 may thereby facilitatea surgeon in determining placement of the virtual implant cup 404relative to the imaged bones at step 302.

In FIG. 5, the graphical user interface 400 includes a 3-dimensionalvisualization of the virtual bone model 502 and of the virtual implantcup 404 placed relative to the virtual bone model 502. The graphicaluser interface 400 includes a previous center point 408 indicating acenter of rotation of the hip joint as determined from the images aswell as a center point 406 of the virtual implant cup 404. The graphicaluser interface 400 thereby facilitates a surgeon in viewing andadjusting the planned pose of the virtual implant cup 404.

As shown in FIGS. 4-5, the graphical user interface 400 includes controlarrows 504 that can be selected to translate or rotate the virtualimplant cup 404 relative to the virtual bone model 502. The graphicaluser interface 400 also includes data fields 506 that show variousinformation that may be of interest to the user, for example, pelvictilt, cup inclination, cup version, stem version, combined version, andsuperior, medial, and anterior distances. The graphical user interface400 of FIGS. 4-5 thereby facilitates planning of implant cup placementrelative to the pelvis at step 302.

At step 304, placement of an implant augment is planned by virtuallyplacing a virtual augment model relative to the virtual implant cup. Forexample, a determination may be made based on the visualization of thevirtual bone model 502 of FIG. 5 or the CT images of FIG. 4 that anaugment may be needed to reliably and securely install the implant cupin the position planed in step 302. An option can be selected via thegraphical user interface 400 to include an augment. FIGS. 6-7 show viewsin the graphical user interface 400 that show a virtual augment model600 and which facilitate selection of a desired placement of the virtualaugment model 600. As shown in FIG. 6, the virtual augment 600 isvisualized in a position relative to the virtual bone model 502 and thevirtual implant cup 404 in a 3-D opaque view. As shown in FIG. 7, thevirtual augment 600 is visualized in a position relative to the virtualbone model 502 in a translucent view and in two CT image views. FIGS.6-7 are described in further detail below.

In most cases, an implant augment has an interior surface thatsubstantially matches an exterior surface of the implant cup, forexample having a degree of curvature or radius substantially equal tothe exterior surface of the implant cup. The augment is therebyconfigured to be placed adjacent to the implant cup and to providestructural support for the implant cup.

As shown in FIG. 6, the graphical user interface 400 includes alock-to-cup button 602. When the lock-to-cup button 602 is selected, thevirtual augment 600 is restricted to a pre-defined spacing relative tovirtual cup 404. For example, the virtual augment 600 may be positionedsuch that the virtual augment 600 is approximately two millimeters fromthe virtual cup 404. This spacing provides a volume which may be filledwith cement or other adhesive during the procedure to couple the augmentto the cup. As shown in FIG. 6, the graphical user interface 400includes an array of control buttons 604 that can be selected to alterthe rotation, version, and inclination of the virtual augment 600 whilepreserving the pre-defined spacing relative to the virtual cup 404.Accordingly, step 304 may include restricting the planned placement ofthe implant augment to a pre-defined spacing relative to the plannedposition of the cup.

As shown in FIG. 7, the graphical user interface 400 shows arepresentation of the virtual augment 600 and the virtual bone model 502without the virtual cup 404. As shown in FIG. 7, the graphical userinterface 400 may facilitate a surgeon in evaluating the contribution ofthe virtual augment 600 to formation of a surface for receiving the cup.CT views 704 show two-dimensional views of the virtual augment 600relative to CT images collected of the patient's hip. The CT images mayshow bone density, a previously-implant cup, other implant components(e.g., screws, plates, etc. used to treat traumatic injury), and/orother useful information. The graphical user interface 400 of FIGS. 6-7thereby facilitate planning of the implant augment relative to theimplant cup and the pelvis. The graphical user interface 400 may alsofacilitate planning of screw trajectories of the implant and theaugment, so that such screw trajectories are considered/plannedsimultaneously. This may ensure that the augment and implant cup arepositioned such that the screws will not interfere with one another orwith any existing hardware (e.g., trauma screws/plates). The screwtrajectories may also be visualized relative to bone density to ensureadequate screw fixation is achieved.

Steps 302 and 304 can thereby result in a planned pose of the implantcup and a planned pose of the implant cup. Such planning (i.e., steps301-304) may occur pre-operatively and/or intraoperatively. Theremaining steps of process 300 occur intraoperatively, i.e., during thesurgical procedure.

At step 306, a registration process is executed to register the relativepositions of the patient's pelvis, the surgical tool(s), the roboticdevice, and/or other tracked probes or instruments. For example, a probemay be tracked by the tracking system 222 and touched to various pointson the pelvis to determine a pose of the pelvis. Various registrationmethods are described above with reference to FIG. 2.

In the case of revision hip arthroplasty procedures, differentregistration workflows may be used depending on whether thepreviously-implanted cup is loose or fixed. FIG. 8 shows a flowchart ofa process 800 for registration in revision hip arthroplasty procedures,according to an exemplary embodiment.

As illustrated in FIG. 8, if the previous cup is fixed, the liner of theprevious implant (i.e., implanted in a previous procedure) is removed atstep 802. At step 804, the location of the pelvis is registered via theprevious implant cup, which is fixed to the pelvis. For example, atracked probe can be touched to various locations on the previousimplant cup to determine a pose of a surface of the previous implantcup. As another example, intra-operative imaging (e.g., x-ray) may beused to determine a pose of a surface of the previous implant cup.Because the geometric relationship between the previous implant cup andthe pelvis is fixed and known from the medical images received at step301, such data can be used for registration of the pelvis. A trackedprobe and/or intraoperative imaging may also be used to locate andregister existing hardware (e.g., trauma screws/plates) to facilitateavoidance of such structures during a procedure (e.g., by creatingvirtual control objects around the located positions of suchstructures). Following registration, the previous cup is removed at step806 to allow the revision implant to be installed. In some embodiments,haptic guidance is used to facilitate removal the previous (primary,existing) implant, for example as described in U.S. Patent Application20180014891. For example, a virtual control object can be generated byreferencing a library of implant designs to determine a geometry of therelevant implant, identifying the edges of the previous implant using aprobe, and generating haptic boundaries based on the probed edges.

Also as illustrated in FIG. 8, the previous cup is loose (i.e., notfixed), the previous cup and liner are removed at step 808 prior toregistration of the pelvis. At step 810, the pelvis is registeredwithout the previous cup. For example, a probe may be touched to variouspoints around or in the region from which the previous cup was removed.

To further illustrate the registration of step 306 according to someembodiments, FIGS. 9-10 depict regions of the pelvis that may be usedfor registration in various scenarios. FIG. 9 illustrates a virtual bonemodel 900 that includes a fixed cup, while FIG. 10 illustrates a virtualbone model 1000 in which a loose cup has been removed, leaving anapproximated, smooth surface. FIGS. 9-10 including demarcation ofseveral registration regions, shown as region A 902, region B 1002,region C 1004, and region D 904.

In a scenario with a fixed cup, registration points (i.e., pointstouched by a tracked probe and used for registration) can be taken inregion A 902, which corresponds to a surface of the previously-implantedfixed cup. Such points may be particularly reliable and accessible, asregion A 902 is exposed during surgery to allow for removal of thepreviously-implanted cup. Other points may also be taken, for example inregion D 904 (along the iliac crest) and/or region C 904 (above theacetabulum).

In a scenario with a loose cup, registration points can be taken inregion B 1002, which corresponds to an acetabular surface exposed whenthe loose cup is removed from the patient. For example, registrationpoints may be taken around a rim of region B 1002. The reliability ofsuch points may be dependent on the accuracy of the segmentation of step301 in differentiating the surface of the bone in the pre-operativeimagery from the loose cup, which is removed to expose the surface ofregion B 1002. In some embodiments, registration of the pelvis isachieved in the loose cup scenario without using acetabular registrationpoints (without using registration points in region A 902 or region B904) and by using extra-acetabular registration points (e.g., points inregion C 1004 and/or region D 904).

Registration as conducted at step 306 thereby facilitates a mapping ofthe actual pose of the pelvis in real space to a virtual position of thevirtual bone model 502 in virtual space. The virtually-planned poses ofthe virtual implant augment and the virtual implant cup can then also beassociated with real poses in real space (e.g., relative to a coordinatesystem used by the tracking system 222).

The primary cup (i.e., the existing implant) can then be removed usingstandard techniques. In some cases, removal of the primary cup mayresult in an unexpected defect cavity which was not accounted for theoriginal surgical plan. In such cases, the tracked probe may be used todefine a contour (size, shape, pose, etc.) of the defect cavity, forexample by tracking the location of the probe as the probe is touched tovarious positions on the surface of the defect cavity, traced/paintedalong the defect cavity, etc. The virtual bone model may then be updatedto include a virtual representation of the defect cavity, so that thevirtual bone model substantially matches the actual form of the boneafter primary cup removal. The surgical plan can then be adjusted toaccount for the defect cavity, for example by modifying a size or poseof an augment. Intra-operative registration and bone model updates canalso be used to correct for voids from a segmentation process or clarifyregions of scatter in the original imaging (e.g., CT images).

Similar updates may be made in response to identification other featuresthat may be located and registered intra-operatively, for example poorbone stock, cysts, etc. In some embodiments, custom virtual controlboundaries are automatically generated intra-operatively based on thetracked positions of a probe moved by a user to positions indicating thelocation of a feature desired to be resected (e.g., a cyst). The roboticdevice 220 can then be controlled based on the custom virtual controlboundary to resect the identified feature.

Additionally, in some embodiments, the virtual bone model may be updatedfollowing an initial resection (e.g., osteophyte resection). Forexample, a cutting accessory (e.g., attached to the robotic device 220)may be tracked relative to the bone as the cutting accessory is used toremove an osteophyte or other feature. Based on the tracked movement ofthe cutting accessory, the virtual bone model can be automaticallyupdated to include the modifications made by the cutting accessory byremoving the portions of the virtual bone model corresponding to theresected features. The virtual bone model can thereby be updated toaccurately represent the post-resection bone surface without reimaging.The surgical plan for remaining steps of the procedure can be updatedbased on the updated virtual bone model, or other interventions can beplaned (e.g., bone graft to fill a void, etc.).

At step 308, the robotic device 220 is controlled to ream the acetabulumto prepare a surface of the pelvis to receive the cup in the plannedpose. For example, a virtual control object may be generated based onthe planned pose of the cup (referred to herein as the “cup virtualcontrol object”). For example, the cup virtual control object mayinclude a surface corresponding to an exterior surface of the cup andarranged in the planned pose of the cup. Such a surface of the cupvirtual control object defines a planned bone modification, e.g., aresulting configuration of the bone after a machining (e.g., reaming)process such that the bone is prepared to receive the cup implant in theplanned pose.

The robotic device 220 may be controlled at step 308 using the cupvirtual control object. In some embodiments, the robotic device 220executes autonomous movements as guided by the cup virtual controlobject to move and operate the surgical tool 234 to ream the pelvis toprepare the pelvis to receive the cup in the planned position. In otherembodiments, the robotic device 220 provides haptic feedback to a userto constrain the surgical tool 234 within the cup virtual control objectas a user manipulates the surgical tool 234 to ream the pelvis toprepare the pelvis to receive the cup in the planned position. These andother possible control modalities are described in detail above withreference to FIG. 2.

FIG. 11 shows an example of a graphical user interface 1100 that may begenerated by the processing circuit 260 and displayed on the display 264to facilitate execution of step 308, for example an in embodiment wherethe robotic device 220 is a haptic device. The graphical user interface1100 shows the virtual bone model 502 with a color-coded (e.g., green)or shaded region 1102 indicating areas of the bone that are to beremoved in accordance with the surgical plan. An arrow 1104 indicates acurrent orientation and center point of the surgical tool 234. A toolindicator 1106 indicates that the surgical tool 234 is currentlyoperating (e.g., that the reamer is rotating).

The processing circuit 260 is configured to update the graphical userinterface 1100 in real time using the tracked poses of the pelvis andthe surgical tool 234 from the tracking system 222. For example, thecolor-coded or shaded region 1102 may be reduced in size as the trackingdata indicates that the cutting accessory of the surgical tool 234(e.g., the head of a reamer tool) passes through the corresponding areaof the bone. Completion of the planned bone modification corresponds tofull consumption (reduction to nothing, erasure, etc.) of thecolor-coded or shaded region 1102.

The virtual control object may also be indicated on the graphical userinterface 1100. In some cases, the processing circuit 260 may provide adifferent color-coding (e.g., red) to indicate areas where data from thetracking system 222 indicates that surgical tool 234 violated theconstraints of the virtual control object and modified the bone beyondthe surgical plan.

At step 310, the robotic device 220 is controlled to ream the acetabulumto prepare a surface of the pelvis to receive the implant augment in theplanned pose of the implant augment.

For example, a virtual control object may be generated based on theplanned pose of the augment (referred to herein as the “augment virtualcontrol object”). For example, the augment virtual control object mayinclude a surface corresponding to an exterior surface of the augmentand arranged in the planned pose of the augment. Such a surface of theaugment virtual control object defines a planned bone modification,e.g., a resulting configuration of the bone after a machining processsuch that the bone is prepared to receive the augment implant in theplanned pose.

In some embodiments, the cup virtual control object and the augmentvirtual control object are separate virtual control objects and areapplied sequentially to execute the surgical plan by first preparing thebone to receive the cup and then preparing the bone to receive theaugment. In some cases, the sequence may be reversed, such that therobotic device 220 is controlled to first prepare the bone to receivethe augment using the augment virtual control object and then the cupvirtual control object is applied to control the robotic device 220 toprepare the bone to receive the cup.

In some such embodiments, a different approach orientation for thesurgical tool may be required by the cup virtual control object and theaugment virtual control object. The processing circuit 260 may determinecompletion of the first bone modification (i.e., an end of step 308) andguide the surgical tool from the orientation required by the cup virtualcontrol object into the orientation required by the augment virtualcontrol object, for example using a collapsing haptic boundary, beforeinitiating the second bone modification (i.e., execution of step 310).Additionally, in some embodiments, a change to the surgical tool 234 maybe made between steps 308 and 310, for example such that a first reamerhead with a first size is used to prepare the cup region and a secondreamer head with a second (e.g., smaller) size is used to prepare thebone to receive the augment. The graphical user interface 1100 maydisplay a prompt to make such a change to the surgical tool 234.

In other embodiments, the cup virtual control object and the augmentvirtual control object are combined as a single virtual control objectthat includes surfaces corresponding to both the cup and the augment. Insuch embodiments, steps 308 and 310 can be executed in a unified(simultaneous) manner.

FIG. 12 shows the graphical user interface 1100 as displayed during step310 in an exemplary embodiment. The graphical user interface 1100 showsthe virtual bone model 502 with a color-coded (e.g., green) or shadedregion 1102 indicating areas of the bone that are to be removed inaccordance with the surgical plan during step 310. The virtual bonemodel 502 has been modified by the processing circuit 260 to visualizethe modifications to the actual bone made during step 308. An arrow 1104indicates a current orientation and center point of the surgical tool234. In the example shown, the arrow 1104 has changed orientationrelative to the orientation of the arrow 1104 as shown in FIG. 11. Atool indicator 1106 indicates that the surgical tool 234 is currentlyoperating (e.g., that the reamer is rotating).

To facilitate step 308, the processing circuit 260 is configured toupdate the graphical user interface 1100 in real time using the trackedposes of the pelvis and the surgical tool 234 from the tracking system222. For example, the color-coded or shaded region 1102 may be reducedin size as the tracking data indicates that the cutting accessory of thesurgical tool 234 (e.g., the head of a reamer tool) passes through thecorresponding area of the bone. Completion of the planned bonemodification corresponds to full consumption (reduction to nothing,erasure, etc.) of the color-coded or shaded region 1102.

Steps 308 and 310 thereby result in a bone (e.g., pelvis) prepared toreceive the cup in the pose planned at step 302 and to receive theimplant in the pose planned at step 304.

At step 312, the augment is placed in the planned pose and a matchbetween the actual pose of the augment and the planned pose is verified,for example as illustrated in the example embodiment of FIG. 13. Asshown in FIG. 13, a surgeon has manually placed the augment 1300 in thesurgical site and adjacent the bone in approximately the planned pose. Anavigation probe 1302 is shown as touching a point on the augment 1300.The navigation probe 1302 can be tracked by the tracking system 222,such that the tracking system 222 can ascertain a location of the tip1304 of the probe 1302 relative to other tracked objects, for examplethe bone modified at steps 308-310. By tracking the navigation probe1302 as the navigation probe 1302 is touched to multiple points on theaugment 1300, a pose of the augment 1300 can be determined by thetracking system 222 and the processing circuit 260. In such embodiments,the processing circuit 260 is configured to compare the tracked pose ofthe augment 1300 to the planned pose of the augment from step 304. Theprocessing circuit 260 may cause the display 264 to display anindication that the tracked pose of the augment 1300 matches the plannedpose of the augment and/or provide guidance for modifying the actualpose of the augment 1300 to bring the tracked pose of the augment 1300into agreement with the planned pose of the augment 1300. In otherembodiments, the augment 1300 may be coupled to a tracked inserter tool,such that the processing circuit can use the tracked pose of theinserter tool to facilitate navigation of the augment to the plannedpose. In some embodiments, the inserter tool is supported by the roboticdevice 220 or another robotic arm such that the inserter tool can holdthe augment 1300 in a selected position.

At step 314, the robotic device 220 is controlled to hold the augment inthe planned placement while the augment is coupled to the pelvis, forexample as illustrated in the example embodiment of FIG. 14. As shown inFIG. 14, the augment 1300 is positioned as described with reference toFIG. 13 and step 312. A holder arm 1400 is coupled to the robotic arm232 and is shown as holding a trial cup implant 1402. The robotic arm232 is controlled to force the trial cup implant 1402 against theaugment 1300 to push the augment 1300 against the bone, thereby holdingthe augment 1300 in the planned pose relative to the bone. The augment1300 can then be coupled to the bone. In the example of FIG. 14, asurgical drill 1404 (e.g., a flexible drill) is used to insert one ormore screws through the augment 1300 and into the bone to secure theaugment 1300 to the bone in the planned position. The trial cup implant1402, as held in position by the robotic device 220, can substantiallyprevent movement of the augment 1300 while the screws are inserted,thereby reducing the number of surgeons or surgical assistants needed toconduct the surgery, improving visibility of the surgical field, andimproving accuracy of placement of the augment 1300 relative to thesurgical plan. Although a trial cup implant is used in this embodiment,a final cup implant may also be used in step 314.

In other embodiments, at step 314, the augment 1300 is coupled to theholder arm such that the holder arm can be moved by the robotic device220 to adjust the position of the augment 1300. In such an embodiment,the robotic device 220 is controlled to move the augment 1300 to theplanned pose, for example autonomously or by providing haptic feedbackto a surgeon. In some embodiments, the surgical drill 1404 isrobotically-controlled (e.g., coupled to a second robotic arm) andconfigured to autonomously insert screws through the augment into thebone in accordance with a surgical plan. In some embodiments, a cuttingaccessory of surgical tool 234 can be used (autonomously or under hapticguidance) to prepare pilot holes for screw insertion. In some suchembodiments, a screw insertion accessory can then be mounted to surgicaltool 234 to insert (autonomously or under haptic guidance) bone screwsinto the pilot holes and through the augment.

At step 316, the implant cup is placed in substantially the planned posefor the implant cup (e.g., slightly spaced from the planned pose inanticipation of step 320 described below). In some embodiments, the cupis manually positioned by a surgeon and that position is checked using anavigation probe as described above for the augment with reference tostep 312. In other embodiments, the implant cup is mounted on animpaction arm coupled to the robotic device 220. The robotic device 220is controlled to move the implant cup to substantially the planned pose,for example autonomously or by providing haptic feedback to a user. Forexample, haptic feedback may be provided by constraining the position ofthe implant cup within a virtual control object that collapses (getssmaller, converges) as the implant cup is brought closer to the plannedpose, i.e., such that the implant cup can be moved closer to the plannedpose but not substantially further away from the planned positionrelative to a current position. The implant cup is thereby positionedand oriented in substantially the planned pose.

At step 318, cement is provided between the cup and the augment. Asmentioned above with reference to step 304, the planned pose of theaugment is spaced apart from the planned pose of the cup to allow forcement to be included between the cup and the augment to couple the cupto the augment. By following steps 312-316, the actual positions of thecup and the augment also provide space for cement between the cup andthe augment. Accordingly, process 300 facilitates use of a predictable,consistent, and preferred (planned, clinically-validated, etc.) amountof cement between the cup and the augment.

At step 320, the robotic device is controlled to facilitate cupimpaction to fix the cup in the planned placement. FIG. 15 shows anexample embodiment of the surgical system 200 arranged to execute step320. As shown in FIG. 15, an impaction device 1500 is mounted on therobotic arm 232. The robotic arm 232 is controlled to align theimpaction device 1500 with the planned orientation of the cup and suchthat a distal end 1501 of the impaction device 1500 is in contact withthe cup at substantially the planned position for the cup. FIG. 15 showsthe display device 264 as providing an indication that the impactiondevice 1500 is properly positioned for cup impaction. When the surgicalsystem 200 is in the state shown in FIG. 15, the surgeon may provide ablunt force to a proximal end 1502 of the impaction device 1500. Theforce is transmitted along the impaction device 1500 to impact the cupinto the pelvis. This force causes the cup to be driven into the pelvisto substantially fix the cup relative to the pelvis. The robotic arm 232and information displayed on the display device 264 facilitates asurgeon in accomplishing impaction such that the cup is fixed to thepelvis in the planned pose (i.e., as planned at step 302).

At step 322, the robotic device is controlled to continue to hold thecup in the planned pose for the duration of cement curing (e.g., tenminutes). FIG. 16 illustrates step 322 in an example embodiment, andshows the implant cup 1600 held in position relative to the implantaugment 1300 by a holder arm 1400. The holder arm 1400 may be the samedevice as the impaction device 1500 or a different device. By automatingthis holding task, a surgeon or surgical assistant may advantageouslybecome free to accomplish other tasks relating to the surgicalprocedure. Additionally, robotically-assisted and tracked positioningduring cement curing may ensure that the planned geometric relationshipbetween the cup and the augment is achieved. Furthermore, integrity ofthe cement mantle and unitization of the cup and augment may beoptimized because relative movement is minimized as the cement hardens.

Following step 322, the surgical procedure may proceed followingestablished workflows, for example to position a liner in the cup, toposition a femoral implant in the cup, to repair soft tissue proximatethe hip joint, and to close the surgical incision. The surgical system200 may be configured to assist with some or all of these additionalsteps in various embodiments. Process 300 may thereby improve surgicalefficiency and experience for surgeons, reduce the duration of asurgical procedure, and improve patient outcomes by providing accurateplacement of augments and cups in accordance with personalized surgicalplans.

Although FIGS. 3-16 show embodiments relating to hip arthroplastyprocedures, it should be understood that the systems and methodsdescribed with reference thereto may be adapted for shoulderarthroplasty procedures. For example, an augment, mesh, bone graft, orother supporting structure may be planned and installed at a glenoidfollowing the workflow of process 300. In some embodiments, the augmentmay be customized for a particular patient (e.g., using additivemanufacturing).

Referring now to FIG. 17, a flowchart of a process 1700 for facilitatingthe use of augments in knee arthroplasty procedures is shown, accordingto an exemplary embodiment. Process 1700 can be executed by the surgicalsystem of FIG. 2 in some embodiments. In a total knee arthroplastyprocedure, a tibia is prepared to be coupled to a tibial implant and afemur is prepared to be coupled to a femoral implant. Following theprocedure, the tibial implant and the femoral implant will articulate onone another to provide knee function. One goal of a total kneearthroplasty procedure is to place the tibial and femoral implants inrelative positions that ensure a full range of motion of the kneewithout pain or discomfort to the user. Another goal of a total kneearthroplasty procedure is to ensure that the tibial and femoralcomponents are coupled to the tibia and femur is such a way as towithstand loads from functional use of the knee (e.g., standing,walking, running, biking, etc.). Accordingly, in some cases (e.g., bonedecay, revision knee procedures, etc.) it may be desirable to use one ormore augment components in addition to the tibial or femoral implants toprovide structural support for the implants and facilitate placement ofthe implants in the preferred poses to improve patient outcomes.

At step 1702 of process 1700, a trial implant or template is physicallypositioned in a desired pose relative to a bone (e.g., a femur ortibia). In some cases, one or more cuts or other modifications may havebeen made to the bone during the knee arthroplasty procedure before step1702. At step 1702, various tests may be perform to determine whetherthe trial implant is in a desired (proper, clinically-advantageous,etc.) pose. For example, a ligament balancing test may be performed.

When the trial implant has been positioned in the desired pose, at step1704 a pose of a tracked probe is tracked while the probe is used totouch or trace one or more lines or points on the trial implant. Theposition and orientation of the tracked probe relative to a trackedposition and orientation of the bone can be determined by a registrationprocess as described above with reference to FIG. 2. FIGS. 18-21illustrate example, non-limiting embodiments of step 1704.

As shown in FIGS. 18 and 19, a tibial template 1800 is positioned on atibia 208. As shown in FIG. 18, A probe 1802 is traced along an anteriorcurve 1804 of the tibial template 1800, an inner profile 1806 of thetibial template 1800, and anterior ridges 1808 of the tibial template1800. As shown in FIG. 19, a probe is touched to various points on thetibial template 1800, including headed nail holes 1900, tibial alignmenthandle dimple 1902, anterior reference marks 1904, and anterior nailholes 1906. Any combination of lines and points as shown in FIGS. 18-19can be used at step 1704 for collecting points or lines at the tibialtemplate 1800, or on another instrument or instruments fixed in positionrelative to the tibial template 1800.

As shown in FIGS. 20-21, a femoral trial 2000 is used. FIG. 20 shows theprobe 1802 used to trace the intercondylar notch 2002 of the femoraltrail 2000. FIG. 21 shows the probe 1802 used to touch peg holes 2100.Any combination of lines and points as shown in FIGS. 20-21 can be usedat step 1704 for collecting points or lines on the femoral trial 2000.

At step 1706, the pose of the trial implant in virtual space relative toa tracked pose of the bone (e.g., represented by a virtual model of thebone) is determined. For example, based on the tracked position of theprobe 1802 when the various lines or points are touched at step 1704, amodel of the trial implant can be oriented and positioned in virtualspace relative to the virtual model of the bone. Accordingly, the pointsand lines used at step 1704 (and shown in FIGS. 18-21) are selected toprovide sufficient data for accurate determination of the pose of thetrial implant at step 1706.

In the example described herein, the pose of the trial implant is usedas the planned pose for the implant (i.e., implant to be left in thepatient after the procedure). In other examples, an offset or otheradjustment may be made between the pose of the trial implant and theplanned pose of the implant.

At step 1708, one or more bone modifications are planned (e.g.,automatically by the processing circuit 260). The planned bonemodification(s) prepares the bone to be coupled to an augment and toreceive the augment and the implant such that the implant is positionedin the planned pose (e.g., the pose of the trial implant determined atstep 1706). For example, an augment may be used to correct for bone lossor weakness on a first side of a bone. The augment may be selectedautomatically by the processing circuit 260 (e.g., from a set ofpossible augments of various sizes, types, shapes, etc.) based the poseof the trial implant and, in some cases, other pre- or intra-operativedata. In such a case, a bone modification may be planned to remove acorresponding section of bone to allow for an augment to be securelyplaced to reinforce the connection between the implant and the bone.Various other updates, additions, etc. to the surgical plan may also bemade at step 1708.

To facilitate explanation of step 1708, FIGS. 22-23 illustrate implantsfor knee arthroplasty procedures with augments. FIG. 22 shows a tibialimplant 2200 and a tibial augment 2202. If the tibial augment 2202 isdesired, at step 1708 a cut is planned to remove bone from the tibia tocreate space for the tibial augment 2202 to be received by the tibia208. FIG. 23 shows a femoral implant 2204 with a pair of femoralaugments 2206. If the femoral augments 2206 of FIG. 23 are desired, apair of planar cuts are planned at step 1708 to remove bone from thefemur to provide space for the pair of femoral implants 2204. Othertypes of cuts and resulting shapes (e.g., a volume reamed with a burr)may be used in other embodiments in accordance with the surface contoursof the corresponding implant(s) and augment(s) used in a givenprocedure. For example, for different types of augments (e.g., coneaugments, stems, etc.) corresponding resection shapes can be executed atstep 1708.

At step 1710, the trial implant is removed from the surgical field. Atstep 1712, the robotic device 220 is controlled to facilitate theplanned bone modifications. For example, the robotic device 220 mayprovide haptic feedback to facilitate a surgeon in executed the plannedbone modifications using a surgical tool coupled to the robotic device220 as described with reference to FIG. 2. As another example, therobotic device 220 may be controlled to autonomously execute the plannedbone modification.

At step 1714, the augment and the implant are installed such that theimplant is placed consistent with the desired pose of the trial implantascertained at steps 1704-1706. In some embodiments, the augment and theimplant are manually placed and the positions are checked using atracked probe as for the trial implant at step 1704. In someembodiments, the robotic device 220 is controlled to hold the augmentand/or implant in the planned pose and/or control a drill or other toolto facilitate and/or automate coupling of the augment and/or implant tothe patient's bone (femur or tibia in the case of knee arthroplasty).

Process 1700 thereby provides for a robotically-assisted kneearthroplasty procedure that includes intraoperative planning andplacement of an augment for either the tibial implant or the femoralimplant. It should be understood that process 1700 and various othersystems and methods described herein may be adapted for variousindications, various surgical procedures, various anatomical regions,etc.

In some embodiments, data is collected relating to the planning andprocedures conducted using the systems and methods described herein. Forexample, details such as the types of implants used, bone density,ligament balancing measurements, final implant placement (angle,anterior/posterior placement, medial/lateral placement, placement withrespect to a joint line, mechanical and anatomic axis positions, etc.),among other possibilities, can be collected during planning of theprocedures. Post-operative outcomes may also be collected. Thepost-operative outcomes may then be compared to the other data toprovide insights into improved execution and implementation of thesystems and methods described herein.

The construction and arrangement of the systems and methods as shown inthe various exemplary embodiments are illustrative only. Although only afew embodiments have been described in detail in this disclosure, manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, use of materials, colors, orientations, etc.). For example,the position of elements may be reversed or otherwise varied and thenature or number of discrete elements or positions may be altered orvaried. Accordingly, all such modifications are intended to be includedwithin the scope of the present disclosure. The order or sequence of anyprocess or method steps may be varied or re-sequenced according toalternative embodiments. Other substitutions, modifications, changes,and omissions may be made in the design, operating conditions andarrangement of the exemplary embodiments without departing from thescope of the present disclosure.

As utilized herein, the terms “approximately,” “about,” “substantially,”and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and areconsidered to be within the scope of the disclosure.

1. A system for facilitating arthroplasty procedures, comprising: arobotic device; a cutting tool configured to interface with the roboticdevice; and a processing circuit communicable with the robotic deviceand configured to: obtain a surgical plan comprising a first plannedposition of an implant and a second planned position of an implantaugment relative to a bone of a patient by: obtaining images of the boneand a previous implant coupled to the bone; segmenting the images todifferentiate the bone and the previous implant; and generating thesurgical plan using the segmented images; determine a planned bonemodification configured to prepare the bone to receive the implant inthe first planned position and the implant augment in the second plannedposition; generate one or more virtual objects based on the planned bonemodification; control the robotic device to constrain the cutting toolwith the one or more virtual objects while the cutting tool interfaceswith the robotic device and is operated to modify the bone in accordancewith the planned bone modification.
 2. The system of claim 1, whereinthe one or more virtual objects comprise a virtual object comprising aream surface, the ream surface corresponding to both the implant and theimplant augment.
 3. The system of claim 1, wherein the one or morevirtual objects comprise a first virtual object comprising a cup surfacecorresponding to the implant and a second virtual object comprising anaugment surface corresponding to the augment implant.
 4. The system ofclaim 3, wherein the processing circuit is configured to control therobotic device to constrain the cutting tool with the one or morevirtual objects by sequentially: selecting the first virtual object andconstraining the cutting tool with the first virtual object; andselecting the second virtual object and constraining the cutting toolwith the second virtual object.
 5. The system of claim 1, comprising: aholder arm configured to be coupled to the robotic device; wherein theprocessing circuit is configured to control the robotic device toposition the holder arm to temporarily hold the implant augment at thebone in the second planned position to facilitate fixation of theimplant augment to the bone.
 6. (canceled)
 7. The system of claim 1,comprising a tracking system configured to track relative positions ofthe bone and the robotic device, the tracking system configured toregister a pose of the bone based on a measured pose of the previousimplant.
 8. The system of claim 1, wherein the processing circuit isconfigured to: generate a virtual bone model based on the segmentedimages; virtually position a virtual implant relative to the virtualbone model and a virtual representation of the previous implant todefine the first planned position of the implant; virtually position avirtual implant augment relative to the virtual implant to define thesecond planned position of the implant augment.
 9. The system of claim8, wherein the processing circuit is configured to require apre-determined spacing between the virtual implant augment and thevirtual implant.
 10. The system of claim 8, wherein the processingcircuit is configured to generate a graphical user interface that showsthe virtual bone model, the virtual implant, and the virtual implantaugment.
 11. The system of claim 10, wherein the graphical userinterface shows one or more screw trajectories.
 12. The system of claim1, comprising a tracking system and a probe, the tracking systemconfigured to determine a position of the probe relative to the bone;wherein the control circuit is configured to determine whether theimplant augment is in the second planned position based on the positionof the probe relative to the bone.
 13. A method, comprising, obtaining asurgical plan comprising a first planned position of an implant cup anda second planned position of an implant augment relative to a bone of apatient by: obtaining images of the bone and a previous implant coupledto the bone; segmenting the images to differentiate the bone and theprevious implant; and generating the surgical plan using the segmentedimages; determining a planned bone modification configured to preparethe bone to receive the implant cup in the first planned position andthe implant augment in the second planned position; generating one ormore virtual objects based on the planned bone modification; controllinga robotic device using the one or more virtual objects to facilitatemodification of the bone with a surgical tool interfacing with therobotic device in accordance with the planned bone modification.
 14. Themethod of claim 13, wherein controlling the robotic device using the oneor more virtual object comprises confining the surgical tool with theone or more virtual objects.
 15. The method of claim 13, wherein the oneor more virtual objects comprise a virtual object comprising a reamsurface corresponding to both the implant cup and the implant augment.16. The method of claim 13, wherein the one or more virtual objectscomprise a first virtual object comprising a cup surface correspondingto the implant cup and a second virtual object comprising an augmentsurface corresponding to the implant cup.
 17. The method of claim 16,wherein controlling the robotic devices comprises: selecting the firstvirtual object and using the first virtual object to constrain thesurgical tool; determining that the bone is prepared to receive theimplant cup; and selecting the second virtual object and using thesecond virtual object to constrain the surgical tool.
 18. The method ofclaim 13, comprising controlling the robotic device to cause the roboticdevice to hold the implant augment at the bone in the second plannedposition to facilitate fixation of the implant augment to the bone. 19.(canceled)
 20. The method of claim 13, wherein obtaining the surgicalplan comprises requiring a pre-determined spacing between the virtualimplant augment and the virtual implant cup.